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Oh, Fuel injection, I hate you so much right now...

So a little bit of good news. Went out this morning to start the jeep and it fired right up! Apparently cleaning the EGR helped. We'll see how it goes driving to work with the stall issues. If it is indeed the EGR, then I will be getting the screened gasket as was mentioned and a new EGR in the very near term
 
So I drove it to work today. Definitely an improvement after cleaning the EGR. Still stalled out twice on me, but started every time, even after sitting for a few hours. I'm thinking I hit on the issue. Next plan is to replace the EGR and gasket and see what happens from there.

Also looking at the fuel pressure regulator which is inside the plenum chamber. If theres still issues with hesitating and stalling while driving, then that's where I'm headed next.
 
So I got back to this today and bought a new Idle Air Control (IAC) valve. Replaced in about 5 minutes. Reset the ECM per S10 FSM (neg battery disconnected, key on, key off 5 seconds, key on 10 seconds.) Took it for a test drive and it's still stalling out when I'm driving. Specifically, I will engine brake and as soon as I push in the clutch to take the load off the engine, RPM drops to zero. Bump the clutch and the engine restarts no problem. It's a little frustrating and a distraction while driving. I am relearning to not engine brake, but use the clutch and brake.

Next week I'll be buying a fuel pressure regulator and plenum gasket and getting those replaced. Should be fun.....

I'll get this figured out at some point.
 
Replaced the EGR valve with a brand new one. Swapped the gasket for a screened one. Took it for a test drive and it still stalled out when decelerating.
I guess next is the fuel pressure regulator. Into the plenum I go!

Anyone with any ideas on this would be greatly appreciated. Once I crack the plenum open, I can also check the spider injectors to see if it's leaking there as well. We'll see how it goes.
 
So my jeep started sputtering and coughing while driving this morning. any time there was a load placed on the engine below 2000 rpm. It finally died trying to go up the hill to my house. Would turn over with starter fluid, but not keep running with the gas pedal. EGR, IAC, PCV, and fuel filter have all been replaced. I betting on the fuel pressure regulator. Here's where I'm at now:

Here's a top down look:
 
Did you see any gas in there? Often that whole spider injection assembly needs replaced and it's not cheap. Terrible design.
 
If the regulator is leaking, it'll usually streak the inside of the manifold and also will have hard hot starts. Prime the pump and check to see if it leaks now that the top cover is off.
 
Currently at the parts store picking up a new fuel pressure regulator. The right side of the plenum was darker and nastier than the left. There was a liquid in he bottom of the plenum tha was dark brown. Didnt really smell like fuel and not the consistency of oil. I dunno. I'm gonna replace the regulator tonight and if that doesn't fix it, then tomorrow the fuel pump. There's not much else i can think it could be. It was definitely a fuel issue as it turned over with starter fluid
 
Got the pressure test kit. Hooked it up on the engine side of the fuel filter and after turning on and off a couple times it's reading 30 psi.
 
Between the tank and the filter it reads 0 psi. So filter is crap. The pressure at the engine is from the return line???
 
Thats where i hooked it up this last time. To the inlet side of the filter.
1st time was the outlet side
2nd time was at the engine
3rd was inlet side of filter
 
It isn't anywhere else, so if i've got one, which i'm assuming i do. It's gotta be in the tank. I've got a 33 gal aftermarket and i've never dropped it to look
 
When the pump kicks on, when you key the ignition, you should hear something, right? Because i don't hear anything
 
I'm calling it for tonight. Thank you Mysunnshine for troubleshooting with me. I appreciate the time and patience. I'm going to get back at it first thing tomorrow morning.
I checked 3 times to make sure I didn't have the filter reversed and it wasn't. The arrow on the side was pointing toward the engine and the "OUT" side was facing the engine.
I am going to clean and replace the plenum and get the top end of the engine put back together. I am going to drop the tank and see what I find there. The filter will be getting replaced and I'll return the fuel pressure regulator.
 
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